Kawi2strokes.com Forum

A friend of mine asked me to take a look at the "restored" KD90 he just bought. He said when the bike is in first gear the kick lever jumps up and down but not in the other gears. I took the clutch cover off and the main spring and kick spring guide are installed right so what else could the problem be? And what would make it act up in first gear only? I figured some one here could give me an idea of what to look for when I split the cases(besides broken gears).

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1969 H1, 1971 G3SSA, 1974 G5, 1973 H2A, 1975 S3A, 1975 H1F, 1973 Z1, 1988 HD FLTC, Captain America chopper, 2000 Excelsior Henderson, 1965 Bridgestone BS90

The kicker should be gear connected to the clutch gear, so the problem shouldn't be a problem. I would have to see a manual to see for sure.

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Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........

I found the problem, the output shaft bushing(oil galley)is sheared off on the inside. I can't see why it sheared off though. I have one ordered but do I press or pound the old one out and the new one in?, the case is pretty thin and of course I don't want to break it.

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1969 H1, 1971 G3SSA, 1974 G5, 1973 H2A, 1975 S3A, 1975 H1F, 1973 Z1, 1988 HD FLTC, Captain America chopper, 2000 Excelsior Henderson, 1965 Bridgestone BS90

Glad you found the problem, press and maybe a heat gun to expand the aluminum.

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Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........

You should be able to cut the old one out, and maybe freeze the new one and tap it in.